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Nano-Enabled Catalysts for the Commercially Viable Production of H2O2

Bing ZhouHeadwaters Technology Innovation, LLC.

Lawrenceville, NJ 08648September 26, 2007

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Headwaters Technology Development Principle

Develop future generation technology not only creates value for industry, but also benefits the environment and human health.

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Waste coal conversion into solid alternative fuel

Waste pyrolysis oil from ethylene cracking to value-added chemicals BTX, gasoline and diesel

NOx removal

Sulfur removal

Mercury removal

Direct synthesis of hydrogen peroxide

Green Projects at Headwaters

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Hydrogen Peroxide

A environmental friendly molecule H2O2

Upon decomposition, it releases water and oxygen

H2O2 = H2O + O2

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Current Hydrogen Peroxide Applications

2006 global hydrogen peroxide use as oxidant ~ 2 million tons2005 global hydrogen peroxide production ~ 3.5 million tons

Demand for H2O2 has grown significantly in recent years. But high cost slowed down its replacement of chlorinated oxidants which have serious environmental impacts.

60% Bleaching Agent

22%Manufacturing Chemicals

18%Environmental,Textile, Mining

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Chemical Industry Efforts Since 1970s

A new process to make H2O2

H2 + O2 = H2O2

Clean process Water or Alcohol as working solution No waste generated Water is the only by-product

Hundreds of million dollars invested by chemical companies like Dupont, BASF, Dow, Mitsubishi, Solvey, Degussa, etc.

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Direct Synthesis of H2O2

> 100 patents between 1980s and 1990s

Company Number of Patent

Air Products 11BASF 5Dow Chemical 1DuPont 11ENI 14Eka Nobel 1FMC 3Solvay Interox 6Mitsubishi Gas Chemical 21Shell 1

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HTIs Results vs. Patented Data

Patent Number

Assignee

H2 in Feed

(vol.%)

H2O2 Concentration

(wt%)

H2O2 Selectivity

(%)

US 4,832,938

DuPont

18

8.0

74 US 2002 0025293

ENI

3.6

7.3

74

US 6,375,920

BASF

10

7

82

WO 02/28527

BASF

10

5.5

90

HTI

3.0

5.2

100

US 6,168,775

HTI

3.0

9.0

99

HTI

3.5

11.0

95

Continuous Production

HTI

3.0 7.0

98*

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NxCat Nanotechnology is the Key to HTIs Process

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Maximum productivity at lowest cost

Reduced bi-products and waste

100% selectivity / Green Chemistry

Long life, lower cost catalyst

High efficiency and yield

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NxCat Catalyst Features

4 nm particles -- 2 nm makes water!!

Uniform metal alloy particles -- 50 :1

110 crystal structure 100% selectivity

Highly dispersed low metal loading

-- 10x more productive than competition

Anchored particles >3 year life

DSHP Catalyst

10 nm

2 nm

1

2

4

3

5

NxCatNxCat Nanotechnology is the Key to Nanotechnology is the Key to HTIHTIss Process Process

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Conventional vs. Direct Synthesis ProcessConventional vs. Direct Synthesis Process

Conventional H2O2 Process Direct Synthesis H2O2

Chemical IntermediateHydrogen Peroxide in Solvent

Solvent

Hydrogenation

OxidationExtraction

3Regeneration

Hydrogen H

2

QuinoneQ

Air

WorkingSolution

WS

Hydroquinone

WS HPQ

WS

Water

QWS

HPin water

Distillation

Mixing

Concentrated HP

NxCatNanocatalyst

H2Hydrogen

O2Oxygen

Chemical IntermediateHydrogen Peroxide in Solvent

Solvent

NxCat nanotechnology enables simple manufacturing process with up to 50% lower capital cost and 20% lower H2O2 cost.

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Direct Synthesis of Hydrogen Peroxide Milestones

Sept. 2004: Joint venture with DegussaMar. 2005: Pilot plant operation Oct. 2005: Commercial demonstration plant contraction startedOct. 2006: Commercial demonstration plant operation2007: Data collection for design of 200,000-ton commercial plant 2008: Commercial plant construction scheduled to start2010 and beyond: every other year a new 200,000-ton plant to be built

Commercial Demonstration Plant Hanau Wolfgang, Germany

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Conclusions

Direct Synthesis is an environmental friendly process Reduce energy consumption by a simple and

more efficient process. Low cost H2O2 has potential to replace

chlorinated oxidants that have serious environmental impacts.

Nanotechnology is the key to enable the new cutting edge process for commercially viable production

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Acknowledgements

Environmental Protection AgencyAmerican Chemical SocietyNational Science FoundationDepartment of EnergyEvonik DegussaHTI Team for Direct Synthesis of H2O2

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Direct Synthesis of Hydrogen Peroxide Team

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Presidential Green Chemistry Challenge Award

Headwaters Technology Development PrincipleHydrogen PeroxideCurrent Hydrogen Peroxide ApplicationsChemical Industry Efforts Since 1970sDirect Synthesis of H2O2HTIs Results vs. Patented DataDirect Synthesis of Hydrogen Peroxide MilestonesConclusionsAcknowledgementsDirect Synthesis of Hydrogen Peroxide TeamPresidential Green Chemistry Challenge Award